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Old 07-14-2016, 10:24 PM   #1
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pi swap

Ok im new to the forum. I have questions regarding the pi swap. I have a 1996 gt and1999 heads off a ford expedition that I wanna use. I have the heater coolant tube and the heater nipple.. what else is needed other than the intake. I have a gasket kit as well.
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Old 07-14-2016, 11:54 PM   #2
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I beleive you will need the timing chain cover, altenator bracket, may also need valve covers I think with the 99 head since I think those are Windsor heads and the 96 are Romeo but I could be mistaken been a while since I looked at the list of needed items. If you google it you will find a ton of info and complete lists of what you need.

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Old 07-15-2016, 04:54 AM   #3
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The heads have the 11 bolt valve pattern on the 99 heads. The same as my 96 npi heads. I have read that I can reuse my alt bracket by drilling new holes. And I also read something about there being a t fitting for the new intake a sensor.
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Old 07-15-2016, 01:37 PM   #4
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99 Windsor PI heads should have 13 bolt holes. If you got the heads off a 4.6L, you have NPI heads, only the 5.4s got PI heads that year. 4.6s didn't get them till very late 00.


To answer your question, you need the heads, cam, intake, that coolant tube and that's really it. Everything else is PNP. Only other thing I can think of is you'll need to drill and tap the coolant crossover boss of the PI intake because the 96-98 uses two sensors and the 99-up only has one.
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Old 07-15-2016, 03:35 PM   #5
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The pi heads have diamond ports not the tear drop. And can i use a t fitting for the coolant crossover.I thought I read it somewhere. I just cant find out what it looks like.
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Old 07-15-2016, 10:15 PM   #6
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You can use a T fitting but it looks ghetto as hell. Tapping the crossover is easy. As for the heads... 99 was Windsors and should have 11 bolt holes. If not then they aren't 99s or they aren't PIs. I dunno. If you are sure they are PI heads then roll with them.
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Old 07-16-2016, 11:57 AM   #7
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Theres 4 holes on top and 5 on bottom. Plus the 2 timing chain bolts. Right. So my 96 has romeos. And the pi you are saying they are Windsors.
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Old 07-16-2016, 12:03 PM   #8
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99 4.6expedition heads

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Old 07-16-2016, 12:32 PM   #9
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Those are not windsors for sure, those are Romeos. Which means they are not 99s? Did you see the vehicle they came off of? They also might have been replacement heads if the vehicle they were on suffered a plug blowout which would be good for you. If they are PI heads they'll say PI, easy to tell.
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Old 07-16-2016, 01:31 PM   #10
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Lol. I bought them off eBay. The description said 99expedition 4.6. So does that mean that I should be able to use my same timing chain cover

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Old 07-16-2016, 09:14 PM   #11
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You can swap covers around on any of the 96-04 cars. 96-98 is one type, 99 is 99 only and then 00-04 is the same. But they all bolt onto the blocks/heads.
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Old 07-16-2016, 10:03 PM   #12
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So my 1996 timing cover will work? And how or where do drill this 3/8 pipe threaded hole. I read it in the wright up. But I've never taken anything like that off.

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Old 07-16-2016, 11:02 PM   #13
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I found out that I can use my 96 crossover and put it onto the new pi intake. So no drilling

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Old 07-17-2016, 04:31 PM   #14
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thats good info, should make it easier. The Romeo or Windsor thing is what I was talking about the 96 is a Romeo and would have less bolts than the Windsor so the Romeo valve covers wouldnt work on the Windsor I thought.

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Old 07-17-2016, 05:27 PM   #15
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Yeah there's a vid on YouTube thats shows the whole intake swap. As for heads I should be able to follow my manual.

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Old 07-18-2016, 01:04 AM   #16
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make this your build thread Im sure it will come in handy for others doing this swap or thinking of doing it. You will also get great advice on here and actual quality answers on things

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Old 07-18-2016, 04:38 AM   #17
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Definitely gonna do this swap over winter. Pretty sure I wanna build the block too.

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Old 07-18-2016, 07:25 PM   #18
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What is your budget? Also, get an aluminum block. 75lbs off the nose of the car is a big deal.
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Old 07-18-2016, 07:27 PM   #19
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Once tax season comes I figure about 2000.kits from modmax

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Old 07-18-2016, 07:28 PM   #20
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I'm not sure if I should keep my stock crank

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Old 07-18-2016, 07:29 PM   #21
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I was gonna keep all stock specs internally. Just forged

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Old 07-18-2016, 07:31 PM   #22
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Quote:
Originally Posted by mustang sammy View Post
Once tax season comes I figure about 2000.kits from modmax

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Going to be a lot more than $2k to do it right. And you can piece together you own "kit" for less. Your stock crank, $180 for Boss rods, $650 for Diamond pistons.

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I'm not sure if I should keep my stock crank

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Keep it, its substantially lighter than a forged one and is good for more power than most street cars will see. 750hp and 7K+ RPM.
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Old 07-18-2016, 08:49 PM   #23
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If I kept my same internal specs I can buy the same bearings too right. Are there upgraded bearings? And another thing I have trouble understanding is what dish or cc pistons would I need for turbo or blower applications. I heard of pvc issues.

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